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CN1319149A - Nonwoven backing and carpet comprising same - Google Patents

Nonwoven backing and carpet comprising same Download PDF

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Publication number
CN1319149A
CN1319149A CN99810212A CN99810212A CN1319149A CN 1319149 A CN1319149 A CN 1319149A CN 99810212 A CN99810212 A CN 99810212A CN 99810212 A CN99810212 A CN 99810212A CN 1319149 A CN1319149 A CN 1319149A
Authority
CN
China
Prior art keywords
layer
backing
nonwoven
filaments
polymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN99810212A
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Chinese (zh)
Other versions
CN1210458C (en
Inventor
P·T·库仑
S·T·约翰逊三世
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Freudenberg Performance Materials BV
Original Assignee
Colbond BV
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Filing date
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Application filed by Colbond BV filed Critical Colbond BV
Publication of CN1319149A publication Critical patent/CN1319149A/en
Application granted granted Critical
Publication of CN1210458C publication Critical patent/CN1210458C/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/065—Polyamides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/348—Mechanically needled or hydroentangled
    • Y10T442/3496—Coated, impregnated, or autogenously bonded
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/3504—Woven fabric layers comprise chemically different strand material
    • Y10T442/3512—Three or more fabric layers
    • Y10T442/352—One of which is a nonwoven fabric layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/3528—Three or more fabric layers
    • Y10T442/3594—Woven fabric layers impregnated with a thermoplastic resin [e.g., vinyl polymer, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/3602—Three or more distinct layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/3602—Three or more distinct layers
    • Y10T442/3667—Composite consisting of at least two woven fabrics bonded by an interposed adhesive layer [but not two woven fabrics bonded together by an impregnation which penetrates through the thickness of at least one of the woven fabric layers]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3707—Woven fabric including a nonwoven fabric layer other than paper
    • Y10T442/3724—Needled
    • Y10T442/3764—Coated, impregnated, or autogenously bonded
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3707—Woven fabric including a nonwoven fabric layer other than paper
    • Y10T442/378—Coated, impregnated, or autogenously bonded

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Carpets (AREA)
  • Multicomponent Fibers (AREA)
  • Laminated Bodies (AREA)
  • Woven Fabrics (AREA)

Abstract

本发明涉及包含经粘合剂聚合物粘合的热塑性聚合物长丝或纤维的非织造地毯底衬,其中底衬包含至少一层可辨别的热塑性织造层,一层可辨别的热塑性连续层或一层还含经粘合剂聚合物粘合的长丝或纤维的可辨别的非织造层,该层起降低底衬脱层强度的作用,根据DIN54310测定的脱层强度相对于不含所述可辨别层同类底衬降低至少30%,优选至少50%。虽然根据本发明的未栽绒底衬的断裂强度较先有技术未栽绒底衬为低,但根据本发明的栽绒底衬的断裂强度和伸长率较先有技术栽绒的底衬为高。The present invention relates to a nonwoven carpet backing comprising thermoplastic polymer filaments or fibers bonded by a binder polymer, wherein the backing comprises at least one discernible thermoplastic woven layer, one discernible thermoplastic continuous layer or A distinguishable nonwoven layer also containing filaments or fibers bonded by a binder polymer, which acts to reduce the delamination strength of the backing, measured according to DIN 54310 relative to those without said The discernible layer is reduced by at least 30%, preferably by at least 50%, of the same substrate. Although the breaking strength of the un-tufted backing according to the present invention is lower than that of the prior art un-tufted backing, the breaking strength and elongation of the tufted backing according to the present invention are high.

Description

Non-woven end liner and comprise the carpet of this end liner
The present invention relates to comprise through the bonding filament thermoplastic polymer of binder polymer or the non-woven carpet end liner of fiber.
Comprise manufacturing, come out for many years, for example can from United States Patent (USP) 4842915, know through the non-woven carpet end liner of bonding long filament of for example thermoplastic polymer adhesive or fiber.This patent disclosure relates to the nonwoven fabric that is made of polyester matrix type long filament, and this fabric is suitable for the synthetic tuft base cloth make carpet and can be strengthened by the adhesive component with long filament, fiber, powder and/or the fine particle form of softness.This adhesive component is made of than the polypropylene of low 90 ℃ of polyester matrix type long filament or fiber melting range at least melting range.
For many years, in order to satisfy the more and more stricter requirement of manufacturer and consumer, the non-woven carpet end liner constantly is improved.Important improvement is: fracture strength and elongation at break behind the raising synthetic tuft, tear resistance after improving synthetic tuft and being coated with, the general outward appearance that makes carpet of improving, can repair the defective that produces in the synthetic tuft process and make and be easy to synthetic tuft, promptly in the synthetic tuft process, produce the resistance of lower opposing acupuncture, reduce inclined to one side pin, avoid crude back stitch, the noise that increases looped pile bunch and reduce the synthetic tuft process.
An object of the present invention is to reach described improvement.This purpose realizes in the carpet underlay described in first section, wherein end liner comprises the recognizable thermoplasticity weaving layer of one deck at least, one deck thermoplasticity pantostrat or one deck comprise through the bonding long filament of binder polymer or the non-woven layer of fiber, this can distinguish that layer works to reduce the end liner delamination strength, the delamination strength that records according to DIN54310 reduces at least 30% with respect to not containing the described similar end liner of layer of distinguishing, and preferably at least 50%.
In general, because the acanthopore of synthetic tuft pin can cause break and/or damage, therefore, synthetic tuft can reduce the fracture strength (high initial collapse intensity) of non-woven end liner.And have been found that by (replenish or additional) one deck and can distinguish that layer reaches the reduction of delamination strength that also can reduce the tensile break strength of end liner significantly, the reduction of this intensity looks shortcoming seemingly.Yet this predetermined fracture strength according to the present invention reduces the delamination strength of reduction end liner (promptly by) and has suppressed the fracture strength that causes because of synthetic tuft and the decline of elongation at break.Though the fracture strength according to non-synthetic tuft end liner of the present invention is lower than the non-synthetic tuft end liner of prior art, in fact synthetic tuft end liner according to the present invention has fracture strength and the elongation at break high than prior art synthetic tuft end liner.This phenomenon will be illustrated and confirm by following examples.
Play a part to reduce delamination strength (for example long filament or fiber have than high fluidity and/or low with other layer adhesiveness) on the one hand, the opposing party should have enough laminated cohesive force again so that stand the layer distinguished of (violent) carrying and processing, it can be many different forms, for example dry-laying supatex fabric, wet-laid non-woven fabric or melt-blown fabric.Other example is Woven fabric and pantostrat such as film or paper tinsel.Yet the hot method or the chemical method spunbonded non-woven fabrics that also can carry out acupuncture or Hydroentangled (hydroentangled) are preferred.
Being noted that European patent application EP 822283 has related to comprises the skin/core bi-component (a) and (b) spun-bonded fibre net of two class long filaments, and wherein core component is that fusing point is higher than the polyethylene terephthalate as the adhesive polymer of skin component.Skin polymer (a) class long filament is 1 with (b) weight ratio of class long filament: 3-1: 10.On the fiber web cross section, (a) the class long filament and (b) weight ratio of class long filament between 15-70%, do not wait.Back one ratio does not have significant change on fiber web entire cross section plane, does not perhaps have recognizable boundary, has so just avoided delamination.Therefore, this technology is to promote the technology of delamination to run in the opposite direction with requirement of the present invention.
Japanese patent application JP04-352861 has related to the supatex fabric that is made of composite long fiber A and composite long fiber B, wherein composite long fiber A comprises the polymer a2 that polymer a1 and fusing point are higher than at least 30 ℃ of a1, and composite long fiber B comprises the polymer b2 that polymer b1 and fusing point are higher than at least 30 ℃ of b1.And the fusing point of polymer b1 is higher than at least 20 ℃ of a1.This fabric constitutes by four layers, a ground floor fibre-bearing A, in the second layer fiber A more than fiber B, in the 3rd layer fiber B more than fiber A, the 4th layer of fibre-bearing B.The change in concentration of fiber A and fiber B is the continuous tangible boundary line that do not have, and therefore delamination can not take place.
United States Patent (USP) 3940302 discloses a kind of nonwoven web of making the knotted rug end liner that is suitable for, this fiber web comprises with the polypropylene to be core and to be the bicomponent filament of skin material with copolyamide (" can become in high-pressure saturated steam is adhesive, and core component is unaffected basically under this pressure ") with polypropylene monofilament (homofilaments).Doubling vertically embeds in the fiber web along fiber web.In a preferred embodiment, the concentration of bicomponent filament at least one surperficial thin layer of product is high in this product center, to improve the absorption of end liner surface to dyestuff.
Japan Patent JP09291457 has related to a kind of laminate that comprises the multi-layer fiber layer, and wherein fibrage comprises paracytic type or the skin/core pattern composite long fiber that is had polymer (being high density polyethylene (HDPE) and the high density poly propylene) formation of different melting points by two classes.The content of high density polyethylene (HDPE) in every layer of fibrage is different.This laminate has fabulous bulkiness, feel and tensile strength.
Japan Patent JP06128855 discloses a kind of three-decker supatex fabric that comprises top layer, intermediate layer and backing layer.Top layer and backing layer are to be made of the conjugated type long fiber that contains thermoplastic polymer components A and the thermoplastic polymer components B compatible with A.This long fiber is bonding with the fusion of component A and B component.The intermediate layer only comprises fiber A that is made of A and the fiber B that only is made of B, and wherein these fibers thread form by long stapled branchs of conjugated type.Fiber A and fiber B tangle, and do not have fusion basically.
In framework of the present invention, comprise and two-layerly distinguish that the carpet underlay of layer is a kind of feasible selection, be that preferably therefore, end liner comprises at least three layers can distinguish layer but end liner is embedded with the layer (internal layer) that reduces the delamination strength effect.In this structure, skin can move with respect to another layer (partly), helps to keep the synthetic tuft yarn like this and helps to reach desired stability and other physical property of end liner.
Every layer comprise (thermoplasticity) binder polymer and filament thermoplastic polymer or fiber and also be preferred through the end liner of heat bonding, wherein concentration and/or the tack temperature of binder polymer in working the layer that reduces the delamination strength effect hangs down at least 20% than binder polymer in other layer, preferably at least 30% and/or high 4 ℃, preferably at least 6 ℃.By reducing bondability, delamination strength is reduced effectively, because long filament or fiber in described layer have bigger mobility, so the maintenance of synthetic tuft yarn (being also referred to as " looped pile bunch " or " looped pile maintenance ") has obtained further enhancing.
On the other hand, carefully select binder polymer, the inconsistent binder polymer of binder polymer in selection and the adjacent layer can reduce the cohesiveness to described layer, thereby obtains lower delamination strength.
The fusion of binder polymer or softening temperature are preferably lower than the fusion of long filament or fiber or softening temperature 15-20 ℃, but concerning some polyblend, littler temperature difference may be suitable or or even necessary.
When binder polymer is the part (binder polymer preferably is constituted to the outer surface part of the youthful and the elderly's silk or fiber) of long filament or fiber, this moment, used noun long filament or fiber were meant bicomponent filament or fiber, when long filament or fiber lay down row, binder polymer is to be evenly distributed in the whole also not bonding supatex fabric.Because in fact therefore the even distribution of binder polymer in supatex fabric all can have adhesive to exist in all contact positions of long filament or fiber.Therefore, a large amount of bounding points is arranged, in addition, in the heat bonding process, can also guarantee to each contact point effective supply adhesive.
Bicomponent fiber and long filament or core/integumentary pattern fiber or bilateral fibre are specially adapted to according in the supatex fabric of the present invention.
Another kind of well-adapted method of adding adhesive to thermoplastic filament or fiber be utilize fully by or most of " the bonding long filament of using " or " binder fibre of making by binder polymer ".These are bonding puts together with long filament or binder fibre and other long filament or fiber lay down, is evenly distributed in result in the whole also not bonding supatex fabric so also obtained adhesive.This supatex fabric is also referred to as " two filament nonwoven fabric " sometimes.
Just in this point, the present invention to the form of above-mentioned binder polymer without limits.Adhesive also can different shape for example powdery, emulsion or add to not in binder filaments or the fiber with fine strip body.
Very suitablely make the polymer of binder polymer in the supatex fabric of the present invention and the example of co-polymer is one or more mixture of polymers in polyamide 6, copolyamide, copolyester, polypropylene, co-polypropylene, polyethylene and these polymer.The example of the another kind of material that is suitable for is a polybutylene terephthalate (PBT).Adhesive also can add by morphon, and this monomer is to solidify (being polymerization) in adhesion process.
In other polymer, polyester is very suitable thermoplastic filament or the fiber done.More suitable material also comprises (but not limited) polyamide 6, polyamide 46, polyamide 66, copolyamide and copolyesters.
If working the layer that reduces delamination strength is non-woven fabric layer, binder polymer preferably was lower than 20: 80 with the volume ratio of the polymer that forms long filament or fiber so, more preferably less than 15: 85.In other non-woven fabric layer, described ratio is preferably 20: 80-50: 50, more preferably 20: 80-35: 65.
The line density of long filament or fiber is preferably the 1-25 dtex, is preferably the 5-20 dtex.When line density was lower than about 1 dtex, then non-woven fabric material can be quite closely when higher basis weights (particularly), and this can more fragile end liner also can increase the number of inclined to one side pin in the synthetic tuft process.When line density surpassed about 25 dtexs, then supatex fabric can be " pine " when basic weight (especially low) very, and looped pile keeps and can descend.
According to total basic weight of carpet underlay of the present invention preferably be at least 50 grams/square metre, more preferably be at least 70 grams/square metre.The basic weight that works the layer that reduces the delamination strength effect preferably is lower than 50% of the total basic weight of carpet underlay, more preferably less than 40% of the total basic weight of carpet underlay.
Though the delamination strength of end liner of the present invention is defined as above-mentioned with respect to not containing (replacement or extra) and can distinguishes for the end liner of layer, it is good that the delamination strength of measuring by DIN54310 generally is lower than 6 Ns.
The invention still further relates to the carpet that comprises above-mentioned supatex fabric end liner.This carpet has high intensity and high elongation rate, and more even.
Above-mentioned tack temperature is meant (adhesive) polymer melt and/or softening, and the temperature of the formation bounding point that contacts between long filament or fiber.This tack temperature can be controlled by several different methods, for example reaches by the binder polymer of selecting to have different melting points and/or melt flow index or melt viscosity.
Melt temperature is to adopt well-known DSC (differential scanning calorimetry) technical measurement, wherein with the rate of heat addition heating of about 5 milligrams of samples (in blanket of nitrogen) with 10 ℃ of per minutes.Adopt the peak temperature of the melt endothermic curve that this DSC technology obtains in framework of the present invention, to be called as " melt temperature ".
Noun " recognizable " is though be meant that the long filament of different layers in supatex fabric or some mixing and/or the entanglement of fiber are that inevitably in fact the transition of its adjacent bed of course is not gradual change.Preferably, every layer all be basically uniformly (promptly in whole thickness, form and do not have big gradient) and/or every layer be to plant long filament or fiber or constitute by the long filament or the even blend of fiber of more than one types by single.
The reduction of binder polymer " concentration " can reach by distinct methods in the layer, for example hangs down the skin/core long filament or the fiber of skin/core ratio by employing, or reaches by blend a small amount of " the bonding long filament of using " or " binder fibre ".
Embodiment
All samples all adopt known technology that three layer filaments can be distinguished that layer successively is stacked and placed on the collector surface and forms through spunbond.In each sample, the basic weight of end liner be 120 the gram/square metre.Long filament is entirely to be core with the polyethylene terephthalate and to be the skin/core pattern of skin with the polyamide 6.Carry out heat bonding after placing sample on the gatherer.
Sample 1a and 1b (promptly in the same old way) are made of three layers of identical filament layer, every layer basic weight be 40 grams/square metre, the skin/core volume ratio that constitutes every layer long filament is 26/74, line density is 9 dtexs.(promptly according to the present invention) is made of two-layer identical skin and one deck internal layer sample 2a with 2b, and the skin/core volume ratio that wherein constitutes outer field long filament is 26/74, and the skin of internal layer/core volume ratio is 10/90.The line density of all long filaments is 9 dtexs, three layers basic weight all be 40 the gram/square metre.Sample 3 (also being according to the present invention) is to be made of two-layer identical skin and one deck internal layer, wherein each outer field basic weight be 36 the gram/square metre, skin/core volume the ratio that constitutes outer field long filament is 26/74, line density is 9 dtexs, and the basic weight of internal layer be 48 the gram/square metre, skin/core volume the ratio that constitutes the long filament of internal layer is 10/90, and line density is 6 dtexs.The tack temperature of preparation sample 1a and 2a prepares sample 1b, 2b and sample 3 is low.
Following performance to sample is measured: according to fracture strength and the elongation at break before the DIN53857-2 mensuration synthetic tuft; According to fracture strength and the elongation at break behind the ASTM D2646 mensuration synthetic tuft; Measure delamination strength according to DIN54310; And according to ten experts synthetic tuft sample outward appearance is given a mark, make evaluation with " evenly " or " inhomogeneous ".
Performance before table 1 synthetic tuft
Sample Intensity (MD/CMD)/2 (N/5cm) Percentage elongation (MD/CMD)/2 (%) Delamination strength (N)
The 1a contrast ????334 ????22 ????7.4
The 1b contrast ????324 ????22 ????11.6
2a the present invention ????194 ????11 ????2.3
2b the present invention ????203 ????12 ????4.0
3 the present invention ????166 ????9 ????5.3
Performance behind table 2 synthetic tuft
Sample Intensity (MD/CMD)/2 (1bs) Percentage elongation (MD/CMD)/2 (%) Outward appearance
The 1a contrast ????112 ????65 Inhomogeneous
The 1b contrast ????105 ????64 Inhomogeneous
2a the present invention ????138 ????76 Evenly
2b the present invention ????136 ????72 Evenly
3 the present invention ????144 ????73 Evenly
These experiments clearly illustrate that, though intensity and percentage elongation according to the present invention before the end liner synthetic tuft decrease and (see Table 1, relatively reduced about 35-60% with the contrast end liner), but behind synthetic tuft, still have quite high intensity and percentage elongation (see Table 2, relatively improved about 40%) with the contrast end liner.Simultaneously, the carpet also made with control sample of the outward appearance of the carpet made from the end liner according to the present invention is much even.

Claims (10)

1．一种包含经粘合剂聚合物粘合的热塑性聚合物长丝或纤维的非织造地毯底衬，其特征在于该底衬包含至少一层可辨别的热塑性织造层，一层可辨别的热塑性连续层或一层还含经粘合剂聚合物粘合的长丝或纤维的可辨别非织造层，该层起降低底衬脱层强度的作用，按照DIN54310测定的脱层强度相对于不合所述可辨别层的同类底衬降低至少30％，优选至少50％。1. A nonwoven carpet backing comprising thermoplastic polymer filaments or fibers bonded by an adhesive polymer, characterized in that the backing comprises at least one discernible thermoplastic woven layer, a discernible thermoplastic continuous Layer or a distinguishable nonwoven layer also containing filaments or fibers bonded by a binder polymer, which layer acts to reduce the delamination strength of the backing, measured in accordance with DIN 54310 relative to non-specified The same substrate reduction of the discernible layer is at least 30%, preferably at least 50%. 2．根据权利要求1的非织造底衬，其中所述层是嵌在底衬中的，从而该底衬包含至少三层可辨别层。2. The nonwoven backing according to claim 1, wherein said layers are embedded in the backing such that the backing comprises at least three discernible layers. 3．根据权利要求1或2的非织造底衬，其中所述每层都包含借助粘合剂聚合物经热粘的热塑性聚合物长丝或纤维，和其中粘合剂聚合物在起降低脱层强度作用的层中的浓度和/或粘合温度较其它层中的粘合剂聚合物浓度低至少20％，优选至少30％，和/或较其它层的粘合温度高至少4℃，优选至少6℃。3. The nonwoven backing according to claim 1 or 2, wherein each layer comprises thermoplastic polymer filaments or fibers thermally bonded by means of a binder polymer, and wherein the binder polymer together reduces delamination strength The concentration and/or bonding temperature in the active layer is at least 20%, preferably at least 30%, lower than the adhesive polymer concentration in the other layers, and/or at least 4°C higher than the bonding temperature of the other layers, preferably at least 6°C. 4．根据前述权利要求中任何一项非织造底衬，其中在这些层中的至少一层中的粘合剂聚合物至少构成长丝或纤维的外表面部分。4. A nonwoven backing according to any one of the preceding claims, wherein the binder polymer in at least one of the layers constitutes at least part of the outer surface of the filaments or fibres. 5．根据权利要求4的非织造底衬，其中长丝或纤维是以粘合剂聚合物形成皮的皮/芯型长丝或纤维。5. 4. The nonwoven backing according to claim 4, wherein the filaments or fibers are sheath/core filaments or fibers of the binder polymer forming a sheath. 6．根据前述权利要求的任何一项非织造底衬，其中在这些层中的至少一层中的粘合剂聚合物选自聚酰胺6、共聚酰胺、聚对苯二甲酸丁二醇酯、共聚聚酯、聚丙烯、共聚丙烯、聚乙烯以及这些聚合物的一种或多种的混合物。6. A nonwoven backing according to any one of the preceding claims, wherein the binder polymer in at least one of the layers is selected from the group consisting of polyamide 6, copolyamide, polybutylene terephthalate, copoly esters, polypropylene, copolymerized polypropylene, polyethylene, and mixtures of one or more of these polymers. 7．根据前述权利要求的任何一项非织造底衬，其中构成这些层中至少一层的长丝或纤维的热塑性聚合物选自聚酯、聚酰胺6、聚酰胺46、聚酰胺66、共聚酰胺以及共聚聚酯。7. A nonwoven backing according to any one of the preceding claims, wherein the thermoplastic polymer of the filaments or fibers constituting at least one of the layers is selected from the group consisting of polyester, polyamide 6, polyamide 46, polyamide 66, copolyamide and Copolyester. 8．根据前述权利要求的任何一项非织造底衬，其中长丝或纤维的线密度为1-25分特，优选为5-20分特。8. A nonwoven substrate according to any one of the preceding claims, wherein the filaments or fibers have a linear density of 1-25 decitex, preferably 5-20 decitex. 9．根据前述权利要求的任何一项非织造底衬，其脱层强度低于6牛。9. A nonwoven backing according to any one of the preceding claims, having a delamination strength of less than 6 N. 10．包含根据前述权利要求的任何一项非织造底衬的地毯。10. Carpet comprising a nonwoven backing according to any one of the preceding claims.
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